System and method for manufacturing cross-ply pre-impregnated material

ABSTRACT

A manufacturing system includes a cutting machine, an adhesion machine, and a pick-and-place system. The cutting machine sequentially cuts a continuous length of a unidirectional prepreg into prepreg segments. Each prepreg segment has an opposing pair of segment cut edges that are non-parallel to a lengthwise direction of the unidirectional prepreg. The adhesion machine has a conveyor belt and an adhesion station. The pick-and-place system sequentially picks up the prepreg segments from the cutting machine, and places the prepreg segments in end-to-end relation on the conveyor belt, and in an orientation such that the segment cut edges are generally parallel to a lengthwise direction of the conveyor belt. The conveyor belt feeds the prepreg segments to the adhesion station. The adhesion station adheres the prepreg segments to a continuous length of a backing material, thereby resulting in a continuous length of a backed cross-ply prepreg.

CROSS-REFERENCE TO RELATED APPLICATION

This non-provisional application claims priority to pending U.S.Provisional Application Ser. No. 63/181,082, entitled SYSTEM AND METHODFOR MANUFACTURING CROSS-PLY PRE-IMPREGNATED MATERIAL, filed Apr. 28,2021, and which is incorporated herein by reference in its entirety.

FIELD

The present disclosure relates generally to composite materials and,more particularly, to a system and method for automated manufacturing ofa cross-ply pre-impregnated composite material.

BACKGROUND

The manufacturing of a composite part typically involves the laminationof multiple plies of fiber-reinforced polymer matrix material. Eachlayer is comprised of reinforcing fibers that are pre-impregnated withresin (e.g., prepreg). The fibers in each ply of a composite part aretypically oriented at a different fiber angle than the fiber angle ofadjacent plies, as a means to optimize the strength and stiffnessproperties of the composite part, and to improve the quality of thecured composite part. For example, a composite part may include 0-degreeplies, and cross-directional plies which typically comprise −45-degreeplies, +45-degree plies, and 90-degree plies.

Unidirectional prepreg is a type of prepreg in which the fibers areoriented parallel to the lengthwise direction of the material (i.e., a0-degree fiber angle). Unidirectional prepreg tape is available incontinuous lengths, and is supported on a backing layer and is wound ona roll for use in automated layup equipment. Rolls of unidirectionalprepreg tape are available in different widths. For example,unidirectional prepreg tape is typically available in widths of up to 12inches or more for use in an automated tape laying (ATL) machine.

ATL machines are very efficient in laying up long courses ofunidirectional prepreg tape to form 0-degree plies of a composite part.However, the use of unidirectional prepreg tape in an ATL machine to layup short courses (e.g., less than 5 feet) of cross-directional plies ofa long composite part requires that the ATL machine traverses the partnumerous times as each cross-directional ply is laid up. The numerousstops and starts required of the ATL machine for laying up eachcross-directional ply significantly increases the total amount of timerequired to complete the layup process. In addition, the ATL machinerequires excessive turn-around space at the end of eachcross-directional ply.

As can be seen, there exists a need in the art for a system and methodfor manufacturing continuous lengths of cross-directional prepregmaterial on a backing layer for use in an ATL machine, to thereby avoidthe need for laying up numerous short courses traversing a compositepart. Ideally, the system is capable of manufacturing multi-layercross-ply prepreg material, such as dual-layer cross-ply prepreg (ortriple-layer cross-ply prepreg, or quadruple-layer cross-ply prepreg,etc.), to further reduce the amount of time required for laying up thecross-directional plies of a composite part.

SUMMARY

The above-noted needs associated with cross-ply prepreg material areaddress by the present disclosure, which provides a manufacturing systemfor manufacturing a backed cross-ply prepreg. The manufacturing systemincludes a cutting machine, an adhesion machine, and a pick-and-placesystem. The cutting machine includes a cutting station configured to cuta continuous length of a unidirectional prepreg into prepreg segments.Each prepreg segment has an opposing pair of segment cut edges that arenon-parallel to a lengthwise direction of the unidirectional prepreg.The adhesion machine has a conveyor belt and an adhesion station. Thepick-and-place system is configured to pick up the prepreg segments fromthe cutting machine, and place the prepreg segments in end-to-endrelation on the conveyor belt, and in an orientation such that thesegment cut edges are generally parallel to a lengthwise direction ofthe conveyor belt. The conveyor belt is configured to feed the prepregsegments to the adhesion station. The adhesion station is configured toadhere the prepreg segments to a continuous length of a backingmaterial, thereby transferring the prepreg segments from the conveyorbelt to the backing material, and resulting in a continuous length of abacked cross-ply prepreg.

Also disclosed is a method of manufacturing a backed cross-ply prepreg.The method includes cutting, using a cutting station of a cuttingmachine, a first continuous length of a unidirectional prepreg intofirst prepreg segments. As mentioned above, each prepreg segment has anopposing pair of segment cut edges that are non-parallel to a lengthwisedirection of the unidirectional prepreg. The method also includespicking up, using a pick-and-place system, the first prepreg segmentsoff of the cutting machine, and placing the first prepreg segments inend-to-end relation onto a conveyor belt of an adhesion machine, and inan orientation such that the segment cut edges are generally parallel toa lengthwise direction of the conveyor belt. In addition, the methodincludes feeding, using the conveyor belt, the first prepreg segments toan adhesion station of the adhesion machine, and adhering, using theadhesion station, the first prepreg segments to a continuous length of abacking material.

Additionally disclosed is a further method of manufacturing a backedcross-ply prepreg, comprising cutting, using a cutting machine, a firstcontinuous length of a unidirectional prepreg into first prepregsegments. In addition, the method includes picking up, using apick-and-place system, the first prepreg segments off of the cuttingmachine, and placing the first prepreg segments in end-to-end relationonto a conveyor belt of an adhesion machine, and in an orientation suchthat the segment cut edges are generally parallel to a lengthwisedirection of the conveyor belt. Furthermore, the method includesfeeding, using the conveyor belt, the first prepreg segments to anadhesion station of the adhesion machine. The method also includesadhering, using the adhesion station, the first prepreg segments to acontinuous length of a backing layer, to thereby form a continuouslength of an intermediate backed cross-ply prepreg. Additionally, themethod includes adhering, using the adhesion station, either a secondcontinuous length of a unidirectional prepreg or an end-to-end series ofsecond prepreg segments to the first prepreg segments of theintermediate backed cross-ply prepreg, thereby resulting in a finalbacked cross-ply prepreg.

The features, functions and advantages that have been discussed can beachieved independently in various examples of the present disclosure ormay be combined in yet other examples, further details of which can beseen with reference to the following description and drawings below.

BRIEF DESCRIPTION OF THE DRAWINGS

These and other features of the present disclosure will become moreapparent upon reference to the drawings wherein like numbers refer tolike parts throughout and wherein:

FIG. 1 is a perspective view of a manufacturing system for automatedmanufacturing of a continuous length of a backed cross-ply prepreg,starting from a continuous length of unidirectional prepreg (i.e.,0-degree prepreg);

FIG. 2 is a further perspective view of the manufacturing system of FIG.1, which includes a cutting machine, a pick-and-place system (e.g., arobotic device), and an adhesion machine;

FIG. 3 is a side view of the manufacturing system of FIGS. 1-2;

FIG. 4 is a perspective view of an example of the cutting machineshowing a backed unidirectional prepreg drum containing a roll of theunidirectional prepreg supported on a backing layer, and furtherillustrating a backing layer collection drum for collecting the backinglayer as the unidirectional prepreg is drawn off the backedunidirectional prepreg drum;

FIG. 5 is a side view of the cutting machine of FIG. 4;

FIG. 6 is an enlarged view of the portion of the cutting machineidentified by reference numeral 6 of FIG. 4, and illustrating apneumatic dancer;

FIG. 7 is an enlarged view of the portion of the cutting machineidentified by reference numeral 7 of FIG. 4, and illustrating a niproller assembly;

FIG. 8 is a side view of an example of the cutting machine in anarrangement wherein the backing layer collection drum is locatedproximate the cutting station;

FIG. 9 is a sectional view taken along line 9-9 of FIG. 8;

FIG. 10 is an enlarged view of the portion of the cutting machineidentified by reference numeral 10 of FIG. 4, and illustrating a cuttingstation having a turntable supporting a cutting device mounted on acutting device actuator;

FIG. 11 shows the cutting station of FIG. 10, and illustrating thecutting device and cutting device actuator rotated, via the turntable,to an angle of −45° relative to a lengthwise direction of theunidirectional prepreg;

FIG. 12 shows the cutting device and cutting device actuator rotated,via the turntable, to an angle of +45° relative to the lengthwisedirection of the unidirectional prepreg

FIG. 13 is a perspective view of an example of a cutting surfaceconfigured to support the unidirectional prepreg during cutting by thecutting device;

FIG. 14 is an exploded perspective view of the example of the cuttingsurface of FIG. 13, illustrating an upper plate, a lower plate, and asacrificial cutting material configured to be inserted into the groovesformed in the upper plate and lower plate;

FIG. 15 is a perspective view of an example of a segment delivery systemhaving prepreg clamps configured to transport each prepreg segment fromthe cutting surface to a segment pickup location;

FIG. 16 shows the prepreg clamps transporting a prepreg segment from ahome position to the segment pickup location;

FIG. 17 shows the prepreg clamps returning back to the home positionafter releasing the prepreg segment at the segment pickup location;

FIG. 18 is an enlarged view of a portion of the pick-and-place system(i.e., a robotic device) of FIG. 1, and illustrating an example of avacuum end effector mounted to a robotic arm of the robotic device;

FIG. 19 is a top-down perspective view of the vacuum end effector ofFIG. 18;

FIG. 20 is a bottom-up perspective view of the vacuum end effector ofFIG. 18, and illustrating three vacuum zones (zones A, B, and C) thatare independently activatable with vacuum pressure for engagingdifferent shapes of the prepreg segment;

FIG. 21 is a top schematic view of the vacuum end effector of FIGS.18-20, and showing zones A and B simultaneously activated with vacuumpressure for vacuum pickup of a 90-degree prepreg segment;

FIG. 22 is a top schematic view of the vacuum end effector showing zonesB and C simultaneously activated with vacuum pressure for vacuum pickupof a −45-degree prepreg segment;

FIG. 23 is a top schematic view of the vacuum end effector rotated 45°relative to the orientation in FIG. 21, and showing zones A and Bsimultaneously activated with vacuum pressure for vacuum pickup of a+45-degree prepreg segment;

FIG. 24 is a top view of the robotic device and portions of the cuttingmachine and adhesion machine, and illustrating a −45-degree prepregsegment at the segment pickup location on the cutting machine, andfurther illustrating an example of the robotic device having the vacuumend effector;

FIG. 25 shows the vacuum end effector picking up the −45-degree prepregsegment at the segment pickup location of the cutting machine;

FIG. 26 shows the vacuum end effector rotated 45° relative to theorientation in FIG. 25, and showing the vacuum end effector placing the−45-degree prepreg segment on the adhesion machine;

FIG. 27 shows the −45-degree prepreg segment on the conveyor belt of theadhesion machine;

FIG. 28 is a perspective view of an example of the adhesion machine;

FIG. 29 is a side view of the adhesion machine of FIG. 28;

FIG. 30 is an enlarged view of the portion of the adhesion machineidentified by reference numeral 30 of FIG. 28, and illustrating anexample of a heating device configured to heat the backing materialand/or the prepreg segments;

FIG. 31 is a perspective view of the adhesion machine showing an exampleof a backing material drum containing a roll of backed material, whichis shown threaded through the adhesion machine, and further illustratinga cross-ply material collection drum for collecting the backed cross-plyprepreg resulting from the adhesion of the prepreg segments to thebacking material;

FIG. 32 is a perspective view of the portion of the adhesion machineidentified by reference numeral 32 of FIG. 28, and illustrating aninitial compaction stage and a secondary compaction stage configured toapply compaction pressure for curing the prepreg segments to the backingmaterial;

FIG. 33 is a perspective view of the portion of the adhesion machineidentified by reference numeral 33 of FIG. 28, and illustrating anexample of a tension-measuring device configured to measure tension loadin the backed cross-ply prepreg prior to winding onto the cross-plymaterial collection drum;

FIG. 34 is a flowchart of operations included in a method ofmanufacturing a continuous length of a backed cross-ply prepreg;

FIG. 35 is a schematic illustration of 90-degree prepreg segments beingcut from a continuous length of unidirectional prepreg via the cuttingmachine, re-oriented via the pick-and-place system, and adhered via theadhesion machine to a backing layer that is initially devoid of prepregmaterial;

FIG. 36 is a schematic illustration of −45-degree prepreg segments beingcut from a continuous length of unidirectional prepreg, and adhered to abacking layer initially devoid of prepreg material;

FIG. 37 is a schematic illustration of +45-degree prepreg segments beingcut from a continuous length of unidirectional prepreg, and adhered to abacking layer initially devoid of prepreg material;

FIG. 38 is a schematic illustration of 90-degree prepreg segments beingcut from a first continuous length of unidirectional prepreg,re-oriented, re-oriented, and adhered to a second continuous length of aunidirectional prepreg (i.e., 0-degree prepreg) backed by a backinglayer;

FIG. 39 is a schematic illustration of −45-degree prepreg segments beingcut from a first continuous length of unidirectional prepreg, andadhered to a second continuous length of a unidirectional prepreg backedby a backing layer;

FIG. 40 is a schematic illustration of +45-degree prepreg segments beingcut from a first continuous length of unidirectional prepreg, andadhered to a second continuous length of a unidirectional prepreg backedby a backing layer;

FIG. 41 is a schematic illustration of 90-degree prepreg segments beingcut from a continuous length (i.e., a roll) of unidirectional prepreg(i.e., 0-degree prepreg), re-oriented, and adhered to a continuouslength of a backed cross-ply prepreg comprising a series of −45-degreeprepreg segments backed by a backing layer;

FIG. 42 is a schematic illustration of −45-degree prepreg segments beingcut from a continuous length of unidirectional prepreg, and adhered to acontinuous length of a backed cross-ply prepreg comprising a series of90-degree prepreg segments backed by a backing layer;

FIG. 43 is a schematic illustration of −45-degree prepreg segments beingcut from a first continuous length of unidirectional prepreg, andadhered to a continuous length of a backed cross-ply prepreg comprisinga series of +45-degree prepreg segments backed by a backing layer;

FIG. 44 is a schematic illustration of +45-degree prepreg segments beingcut from a first continuous length of unidirectional prepreg, andadhered to a continuous length of a backed cross-ply prepreg comprisinga series of −45-degree prepreg segments backed by a backing layer;

FIG. 45 is a schematic illustration of +45-degree prepreg segments beingcut from a first continuous length of unidirectional prepreg, andadhered to a continuous length of a backed cross-ply prepreg comprisinga series of 90-degree prepreg segments backed by a backing layer;

FIG. 46 is a schematic illustration of 90-degree prepreg segments beingcut from a first continuous length of unidirectional prepreg, andadhered to the continuous length of a backed cross-ply prepregcomprising a series of +45-degree prepreg segments backed by a backinglayer;

FIG. 47 is a schematic illustration of a continuous length ofunidirectional prepreg (i.e., 0-degree prepreg) being adhered to acontinuous length of a backed cross-ply prepreg comprising a series of90-degree prepreg segments backed by a backing layer;

FIG. 48 is a schematic illustration of a continuous length ofunidirectional prepreg being adhered to a continuous length of a backedcross-ply prepreg comprising a series of −45-degree prepreg segmentsbacked by a backing layer;

FIG. 49 is a schematic illustration of a continuous length ofunidirectional prepreg being adhered to a continuous length of a backedcross-ply prepreg comprising a series of +45-degree prepreg segmentsbacked by a backing layer.

DETAILED DESCRIPTION

Referring now to the drawings which illustrate preferred and variousexamples of the disclosure, shown in FIGS. 1-3 is an example of amanufacturing system 100 for automated manufacturing of a continuouslength of a backed cross-ply prepreg 416. The backed cross-ply prepreg416 comprises at least one layer of end-to-end prepreg segments 150supported on a backing layer 126. The manufacturing system 100 includesa cutting machine 110, an adhesion machine 400, and a pick-and-placesystem 300. The cutting machine 110 is configured to support a roll ofthe continuous length of the unidirectional prepreg 122. Theunidirectional prepreg 122 (e.g., unidirectional prepreg tape) containscontinuous reinforcing fibers 124 (FIGS. 24 and 27) that are oriented ata fiber angle of 0-degrees relative to the lengthwise direction of theunidirectional prepreg 122. The reinforcing fibers 124 arepre-impregnated with resin. The reinforcing fibers 124 may be formed ofany one of a variety of materials such as plastic, glass, ceramic,carbon, metal, or any combination thereof. The resin may be athermosetting resin or a thermoplastic resin, and may be formed of anyone of a variety of organic or inorganic materials. The unidirectionalprepreg 122 is supported on a backing layer 126. The backing layer 126may be a paper material and/or the backing layer 126 may be a polymericfilm.

The cutting machine 110 is configured to peel the backing layer 126 fromthe continuous length of unidirectional prepreg 122, and feed the peeledunidirectional prepreg 122 to a cutting station 230 where theunidirectional prepreg 122 is sequentially cut into prepreg segments150. Each prepreg segment 150 has an opposing pair of segment side edges154 (FIG. 15), and an opposing pair of segment cut edges 152 (FIG. 15).The cutting station 230 cuts the unidirectional prepreg 122 such thatthe segment cut edges 152 are non-parallel to the lengthwise directionof the unidirectional prepreg 122. For example, as described below, thecutting station 230 is capable of cutting the unidirectional prepreg 122at an orientation of −45 degrees, +45 degrees, 90 degrees, or any one ofa variety of other angles, relative to the lengthwise direction of theunidirectional prepreg 122.

The adhesion machine 400 has a conveyor belt 418 and an adhesion station420, and is configured to support a roll of a continuous length of abacking material 404. As described below, the backing material 404 maycomprise a backing layer 126 similar to the above-mentioned backinglayer 126 that the cutting machine 110 peels off of the unidirectionalprepreg 122 prior to cutting into prepreg segments 150. Alternatively,the backing material 404 may comprise a roll of backed cross-ply prepreg416, which may have been previously manufactured by thepresently-disclosed manufacturing system 100, as described below. Evenfurther, the backing material 404 may comprise a continuous length(e.g., a roll) of unidirectional prepreg 122.

The pick-and-place system 300 is configured to sequentially pick up theprepreg segments 150 from the cutting machine 110, and place the prepregsegments 150 in end-to-end relation on the moving conveyor belt 418. Thepick-and-place system 300 places the prepreg segments 150 on theconveyor belt 418 in an orientation such that the segment cut edges 152of the prepreg segments 150 are aligned with each other, and aregenerally parallel to a lengthwise direction of the conveyor belt 418.Once the prepreg segments 150 are placed on the conveyor belt 418, thesegment cut edges 152 become the sides of the backed cross-ply prepreg416 that is produced by the manufacturing system 100. The pick-and-placesystem 300 preferably places the prepreg segments 150 in non-overlappingrelation to each other, and at a maximum gap of 0.10 inch betweenadjacent prepreg segments 150, although the manufacturing system 100 canbe adjusted to accommodate any overlap requirements or gap requirementsbetween the end-to-end prepreg segments 150. In addition, thepick-and-place system 300 preferably orients the prepreg segments 150such that the fiber angles of the prepreg segments 150 are parallel toeach other.

The conveyor belt 418 is configured to feed the series of prepregsegments 150 to the adhesion station 420. In one example, the conveyorbelt 418 is moved at a constant speed, and the backing material 404 ismoved over the conveyor belt 418 in synchronization with the conveyorbelt 418 and/or at the same speed as the conveyor belt 418. The adhesionstation 420 is configured to adhere the prepreg segments 150 to thecontinuous length of the backing material 404, thereby transferring theprepreg segments 150 from the conveyor belt 418 to the backing material404, and resulting in the continuous length of the backed cross-plyprepreg 416 which is wound onto a drum, as described below. In thepresent disclosure, a backed cross-ply prepreg 416 contains a backinglayer 126, and at least one layer of an end-to-end series of prepregsegments 150 of which the reinforcing fibers 124 are orientednon-parallel to the lengthwise direction of the backed cross-ply prepreg416. As shown in FIGS. 35-37 and described below, the manufacturingsystem 100 has the capability to manufacture a single-layer backedcross-ply prepreg 416 (i.e., a single layer of end-to-end prepregsegments 150 defining cross-directional prepreg material on a backinglayer 126). In addition, as shown in FIGS. 38-49 and described below,the manufacturing system 100 has the capability to manufacture adual-layer backed cross-ply prepreg 416 in which at least one of thelayers of prepreg material comprises cross-directional prepreg material.Although not shown in the figures, the manufacturing system 100 also hasthe capability to manufacture a backed cross-ply prepreg 416 having morethan two layers of prepreg material on a backing layer 126. For example,the manufacturing system 100 also has the capability to manufacture abacked cross-ply prepreg 416 containing three or more layers of prepregmaterial on a backing layer 126.

As shown in FIGS. 1-3, the cutting machine 110 is supported on a cuttingmachine framework 112. The adhesion machine 400 is located proximate thecutting machine 110, and is supported on an adhesion machine framework402. The pick-and-place system 300 is located proximate the downstreamend of the cutting machine 110, and proximate the upstream end of theadhesion machine 400. In the example shown, the pick-and-place system300 is a robotic device 302, as described in greater detail below.However, in other examples not shown, the pick-and-place system 300 maybe configured as a gantry system configured to pick up the prepregsegments 150 from the cutting machine 110, reorient the prepreg segments150, and place the prepreg segments 150 onto the conveyor belt 418.Although not shown, the manufacturing system 100 is coupled to and/orincludes a variety of utility lines interconnecting the variouscomponents, and enabling operation of the manufacturing system 100. Suchutility lines may include pneumatic lines, vacuum lines, compressed airlines, data and communication lines, and power lines, all of which havebeen omitted, for clarity of the figures.

In the example of FIGS. 1-3, the cutting machine 110 is positioned inalignment with the adhesion machine 400, such that the direction ofmovement of the unidirectional prepreg 122 through the cutting machine110 is aligned with the direction of movement of the conveyor belt 418.As described below, aligning the cutting machine 110 with the adhesionmachine 400 allows for the ability to produce a continuous length ofbacked cross-ply prepreg 416 having a first layer of prepreg comprisinga series of prepreg segments 150 on a backing layer 126, and a secondlayer of prepreg comprising a continuous length (i.e., uncut) ofunidirectional prepreg 122 (i.e., 0-degree fiber angle) on top of thefirst layer of prepreg segments 150. In this regard, the robotic device302 is positioned to the side of the manufacturing system 100 to avoidinterfering with the unidirectional prepreg 122 (i.e., uncut) passingfrom the cutting machine 110 to the adhesion machine 400.

However, in other examples not shown, the manufacturing machine may beconfigured such that the cutting machine 110 and the adhesion machine400 are non-aligned with each other. For example, the cutting machine110 and the adhesion machine 400 may be positioned side by side, and maybe oriented such that the downstream end of the cutting machine 110 islocated immediately adjacent to the upstream end of the adhesion machine400, to allow the pick-and-place system 300 (e.g., a robotic device 302)to easily transfer the prepreg segments 150 from the cutting machine 110to the conveyor belt 418. However, in such a side-by-side arrangement, acontinuous length of unidirectional prepreg 122 (i.e., uncut) isincapable of passing from the cutting machine 110 to the adhesionmachine 400.

Referring to FIGS. 4-5, shown is an example of the cutting machine 110,which includes a backed unidirectional prepreg chuck 116 configured tosupport a backed unidirectional prepreg drum 114. The backedunidirectional prepreg drum 114 is configured to support a roll of thecontinuous length of unidirectional prepreg 122, which itself issupported on a backing layer 126 as mentioned above. In addition, thecutting machine 110 includes a backing layer collection chuck 134configured to support a backing layer collection drum 132. The backinglayer collection drum 132 is configured to collect the backing layer 126as the backing layer 126 is peeled off of the unidirectional prepreg 122as the unidirectional prepreg 122 is fed through the cutting machine110. The backed unidirectional prepreg chuck 116 and the backing layercollection chuck 134 are each rotatably driven by a chuck servomotor 118(FIG. 1). Each chuck includes pneumatic clamps mounted on separate legsof the chuck. When a drum is mounted on a chuck, compressed air isprovided to the pneumatic clamps to urge the pneumatic clamps againstthe inner wall of the drum, thereby securing the drum to the chuck.Removal of the drum from the chuck is effected by decoupling thecompressed air source from the pneumatic clamps.

The cutting machine 110 includes a plurality of rollers (e.g., idlerrollers 182, dancer roller 184, etc.) for supporting the unidirectionalprepreg 122, and to facilitate directional changes of the unidirectionalprepreg 122 through the cutting machine 110. In some examples of themanufacturing system 100, the rollers may each include circumferentialalignment ridges (not shown) protruding from the cylindrical outersurface of the rollers. A pair of the circumferential alignment ridgesare located respectively on opposing ends of each roller. Thecircumferential alignment ridges are spaced apart at a width that isequivalent to the width of the unidirectional prepreg 122, and areconfigured to maintain the alignment of the unidirectional prepreg 122as the unidirectional prepreg 122 moves through the cutting machine 110.The adhesion machine 400 may also include rollers (e.g., idler rollers182) that have circumferential alignment ridges. On the adhesion machine400, the circumferential alignment ridges are spaced apart by a distanceequivalent to the width of the backing material 404, and provide a meansfor maintaining the backing material 404 in alignment with the prepregsegments 150 on the conveyor belt 418 during adhesion.

Referring to FIGS. 4-7, the cutting machine 110 includes a nip rollerassembly 200 configured to draw the unidirectional prepreg 122 throughthe cutting machine 110, and feed a predetermined length of theunidirectional prepreg 122 into the cutting station 230. In the exampleshown, the nip roller assembly 200 has opposing nip rollers 202 whichare positioned relative to each other to define a roller interface 210between the nip rollers 202. In the example shown, the nip rollers 202include an upper nip roller 204 and a lower nip roller 206.

The nip roller assembly 200 further includes a nip roller servomotor 208having a rotary encoder (not shown). The nip roller servomotor 208 isconfigured to rotatably drive the lower nip roller 206. In the exampleshown, the lower nip roller 206 is a rigid cylinder (e.g., solidaluminum) having a textured outer surface (e.g., sandblasted) configuredto frictionally engage the backing layer 126 that supports theunidirectional prepreg 122. The upper nip roller 204 is freelyrotatable, and is formed of a softer, elastomeric material for bearingagainst the unidirectional prepreg 122 without damaging the material.For example, the upper nip roller 204 may be comprised ofethylene-propylene-diene-monomer (EPDM) rubber or other elastomericmaterial.

The nip roller assembly 200 includes a nip roller actuator 212, whichmay comprise a pneumatically-driven linear actuator. The nip rolleractuator 212 extends between an actuator mounting bracket 196 and a niproller support fitting 214 (FIG. 7). The nip roller actuator 212 isconfigured to move the upper nip roller 204 toward and away from thelower nip roller 206, between a closed position and an open position. Inthe open position, the unidirectional prepreg 122 may be threaded intothe roller interface 210, after which the nip roller actuator 212 movesthe upper nip roller 204 downwardly into the closed position, therebyclamping onto the unidirectional prepreg 122. When prompted by thecontroller 102 (FIG. 1) of the manufacturing system 100, the nip rollerservomotor 208 is activated to rotate the lower nip roller 206, causinga predetermined length of the unidirectional prepreg 122 to be fed intothe cutting station 230 for cutting into a prepreg segment 150. Therotary encoder of the nip roller servomotor 208 provides a means formetering the predetermined length that is extended from the nip rollerassembly 200 into the cutting station 230.

Referring to FIGS. 4-6, the cutting machine 110 further includes apneumatic dancer assembly 180 located between the backed unidirectionalprepreg drum 114 and the nip roller assembly 200. The pneumatic dancerassembly 180 is configured to apply a substantially constant tensionload on the unidirectional prepreg 122 as the nip roller assembly 200draws the unidirectional prepreg 122 off of the backed unidirectionalprepreg drum 114. In this regard, the pneumatic dancer assembly 180maintains a limited amount of tension (e.g., approximately 10 pounds offorce) on the unidirectional prepreg 122, and avoids exceeding thetension limit, to avoid stretching damage to the unidirectional prepreg122. In addition, the tension in the unidirectional prepreg 122 enablesthe nip roller assembly 200 to dispense a precise length of theunidirectional prepreg 122 into the cutting station 230.

As shown in FIG. 6, the pneumatic dancer assembly 180 includes a pair ofidler rollers 182 and a dancer roller 184. The dancer roller 184 and theidler rollers 182 are located in a manner that provides obtusewraparound angles for the unidirectional prepreg 122 moving through thepneumatic dancer assembly 180, and which allows for accuratelycontrolling the tension load on the unidirectional prepreg 122 andpreventing fraying and other damage to the unidirectional prepreg 122.The pneumatic dancer assembly 180 includes a dancer arm 188, and adancer mounting stand 186 to support the dancer arm 188. The dancer arm188 is pivotally coupled to the dancer mounting stand 186, and has aroller mounting portion 190, and an actuator mounting portion 192. Theroller mounting portion 190 supports the dancer roller 184. A danceractuator 194 extends between the actuator mounting portion 192 and theactuator mounting bracket 196. In the example shown, the dancer actuator194 is a linear actuator, such as a low-stiction air cylinder. Thepneumatic dancer assembly 180 includes a rotational encoder (not shown)that outputs the position of the dancer arm 188 to a control loop (notshown), to thereby provide feedback to the dancer actuator 194 formaintaining substantially constant tension in the unidirectional prepreg122.

Referring to FIGS. 8-9, shown is an alternative arrangement of thecutting machine 110 in which the backing layer collection drum 132 islocated proximate the cutting station 230. In contrast to thearrangement of FIGS. 1-5 in which the backing layer collection drum 132is located immediately adjacent to the backed unidirectional prepregdrum 114, the backing layer collection drum 132 in FIGS. 8-9 is locateddownstream of the nip roller assembly 200 and upstream of the cuttingstation 230, and is configured to peel the backing layer 126 from theunidirectional prepreg 122 as the unidirectional prepreg 122 exits thenip roller assembly 200 prior to entering the cutting station 230. Bypeeling the backing layer 126 off of the unidirectional prepreg 122after exiting the nip roller assembly 200 as shown in FIGS. 8-9, theunidirectional prepreg 122 remains fully supported on the backing layer126 from the point where the unidirectional prepreg 122 spools off ofthe backed unidirectional prepreg drum 114, to the point where theunidirectional prepreg 122 passes through the nip roller assembly 200prior to entering the cutting station 230. By supporting theunidirectional prepreg 122 on the backing layer 126 just prior toentering the cutting station 230, the stability and accuracy of thehandling of the unidirectional prepreg 122 is improved, relative to thearrangement of FIGS. 1-5 where the backing layer collection drum 132 islocated immediately adjacent to the backed unidirectional prepreg drum114. In FIGS. 8-9, the backing layer collection drum 132 is supportedabove the cutting station 230 via a chuck support structure 120. Anidler roller 182 (FIG. 8) is included for redirecting the backing layer126 from the nip roller assembly 200 to the backing layer collectiondrum 132. As mentioned above, the backing layer collection drum 132 isrotatably driven by a chuck servomotor 118, as shown in FIG. 9.

Referring to FIGS. 10-13, shown is an example of the cutting station 230for cutting the continuous length of the unidirectional prepreg 122 intoprepreg segments 150. In the example shown, the cutting station 230 isconfigured to cut the unidirectional prepreg 122 into prepreg segments150 (FIG. 15) that have segment cut edges 152 (FIG. 15) oriented at −45degrees, +45 degrees, or 90 degrees, relative to the lengthwisedirection of the unidirectional prepreg 122. Toward this end, thecutting station 230 includes a cutting assembly 232 supported on acutting assembly frame 234. The cutting assembly 232 includes a cuttingdevice 236, and a turntable 242 (FIG. 10) configured to support thecutting assembly 232. The turntable 242 is configured to lock theorientation of the cutting device 236 relative to the lengthwisedirection of the unidirectional prepreg 122. In the example shown, thecutting device 236 is suspended below the turntable 242. The turntable242 has detents 244 for locking the orientation of the cutting device236 at 90 degrees (FIG. 10), +45 degrees (FIG. 11), or −45 degrees (FIG.12). However, the turntable 242 may include detents 244 at any one of avariety of other angular orientations relative to the lengthwisedirection of the director prepreg, as may be dictated by the desiredfiber angle of the backed cross-ply prepreg 416 to be manufactured bythe manufacturing system 100.

In FIGS. 10-12, the cutting device 236 is shown as a cutting wheel.However in other examples, the cutting device 236 may be configured asan ultrasonic device, a cutting blade, or other cutting deviceconfiguration that provides a high degree of accuracy and repeatabilityin cutting the unidirectional prepreg 122. The cutting device 236 iscoupled to a cutting device carriage 238. The cutting assembly 232includes a cutting device actuator 240 for driving the cutting device236 across the width of the unidirectional prepreg 122 for cutting intothe prepreg segments 150. In the example shown, the cutting deviceactuator 240 is a linear actuator configured as a pneumatic air slide(e.g., a pneumatically-driven actuator). However, the cutting deviceactuator 240 may be configured as a screw drive mechanism, or otheractuator arrangement.

Referring to FIGS. 13-14, the cutting station 230 includes a cuttingsurface 250 for supporting the unidirectional prepreg 122 duringcutting. The cutting surface 250 may be porous or may have a pluralityof pores, and is fluidically coupled to a vacuum source such as acompressed air-powered vacuum generator, or a shop vacuum source orpump. The application of vacuum pressure to the cutting surface 250provides for vacuum coupling of the unidirectional prepreg 122 to thecutting surface 250, and prevents movement of the unidirectional prepreg122 during cutting by the cutting device 236, which allows for precisecutting and a reduction in the risk of damage to the prepreg segments150.

In the example shown in FIGS. 13-14, the cutting surface 250 has anupper plate 254 and a lower plate 256. The lower plate 256 includes achamber, and a recess configured to receive the upper plate 254. Theupper plate 254 and the lower plate 256 are formed of a rigid material(e.g., metallic material, such as aluminum), and each contain grooves258 respectively aligned with the cutting orientations of the cuttingdevice 236 as defined by the detents 244 associated with the turntable242. The grooves 258 are configured to receive a sacrificial cuttingmaterial 260 against which the cutting device 236 bears when cutting theunidirectional prepreg 122. Examples of the sacrificial cutting material260 include, but are not limited to, a non-porous material such asrubber (e.g., EPDM), or a porous material such as Vyon™ that is capableof vacuum coupling to the unidirectional prepreg 122.

The cutting surface 250 is optionally configured to be fluidicallycoupled to a pressurized air source (e.g., a compressed air source) fordischarging air out of the pores or porous surface, as a means forforcing the prepreg segment 150 away from the cutting surface 250.Forcing the prepreg segment 150 away from the cutting surface 250prevents stiction to the cutting service, and thereby promotes slidingtranslation of the prepreg segment 150 off of the cutting surface 250.

Referring to FIGS. 15-17, the cutting machine 110 includes theabove-mentioned segment pickup location 286 where each prepreg segment150 is accessible for pickup by the pick-and-place system 300. Towardthis end, the cutting machine 110 includes a segment delivery system 270configured to transport each prepreg segment 150 from the cuttingsurface 250 to the segment pickup location 286. At the segment pickuplocation 286, the prepreg segment 150 is in an openly accessiblelocation that provides clearance for the pick-and-place system 300 topick up the prepreg segment 150. The segment delivery system 270 islocated immediately downstream of the cutting surface 250.

In FIGS. 15-17, the segment delivery system 270 includes a segmentclamping system 272 comprising a pair of prepreg clamps 274 configuredto clamp onto the side edges of a downstream portion of theunidirectional prepreg 122 prior cutting by the cutting device 236 toproduce a prepreg segment 150. Each prepreg clamp 274 has a prepregclamp actuator 276 for vertically moving the prepreg clamp 274 between aclamped position (FIGS. 15-16) and an unclamped position (FIG. 17). Theprepreg delivery system includes a delivery system support table 282located adjacent to the cutting surface 250, and a delivery systemvacuum table 284 located downstream of the delivery system support table282. The delivery system support table 282 is configured to support theunidirectional prepreg 122 prior to and after cutting into a prepregsegment 150. The delivery system vacuum table 284 is configured to befluidically coupled to a vacuum source for vacuum coupling each prepregsegment 150 to the segment pickup location 286 after being transportedby the segment delivery system 270.

Each one of the prepreg clamps 274 is supported on a linear guide rail278. In addition, the segment clamping system 272 includes a clamptransporter actuator 280, such as a linear actuator (e.g., apneumatically-driven actuator). The clamp transporter actuator 280 iscoupled to the prepreg clamps 274 via a transporter base plate 288 thatis located underneath the delivery system support table 282 and deliverysystem vacuum table 284. The transporter base plate 288 extends betweenand interconnects the lower portions of the pair of prepreg clamps 274.Prior to vacuum coupling the unidirectional prepreg 122 to the cuttingsurface 250, the clamp transporter actuator 280 is configured to apply asmall amount of tension (e.g., less than 10 pounds of force) to theunidirectional prepreg 122 as a means to remove any slack. The tensionload applied to the unidirectional prepreg 122 by the clamp transporteractuator 280 is resisted by the nip roller assembly 200. Once tensionload is applied to the unidirectional prepreg 122, vacuum pressure isactivated at the cutting surface 250, after which the clamp transporteractuator 280 is disabled to thereby stop the application of tension tothe unidirectional prepreg 122. The cutting device 236 is then drivenacross the unidirectional prepreg 122, resulting in a prepreg segment150.

After cutting the unidirectional prepreg 122, the prepreg clamps 274remain clamped to the prepreg segment 150. The vacuum pressure isdeactivated at the cutting surface 250, and the clamp transporteractuator 280 moves the segment clamps along the linear guide rails 278to thereby transport each prepreg segment 150 from the cutting station230 to the segment pickup location 286 (FIGS. 15-16), which may occupyat least a portion of the delivery system vacuum table 284. Upon arrivalat the segment pickup location 286, vacuum pressure is activated at thedelivery system vacuum table 284 to secure the prepreg segment 150 inposition, and the prepreg clamps 274 are moved upwardly into theunclamped position. The clamp transporter actuator 280 returns theprepreg clamps 274 back to the delivery system support table 282 (FIG.15) in preparation for clamping onto another downstream portion of theunidirectional prepreg 122, when fed into the cutting station 230 by thenip roller assembly 200.

Referring to FIGS. 1-3 and 18-27, shown is an example of thepick-and-place system 300 configured as a robotic device 302. However,in another example not shown, the pick-in-place system may comprise anoverhead gantry. As shown in FIGS. 18-27, the robotic device 302 has arobotic arm 304 configured to sequentially pick up the prepreg segments150 at the segment pickup location 286 (FIGS. 24-25), and place theprepreg segments 150 on the conveyor belt 418 in end-to-end relation toeach other, and in an orientation such that the segment cut edges 152 ofthe prepreg segments 150 are aligned with each other, and are parallelto a lengthwise direction of the conveyor belt 418.

As shown in FIGS. 18-27, the robotic arm 304 includes a vacuum endeffector 306 configured for vacuum coupling to the prepreg segments 150.The vacuum end effector 306 includes a vacuum plenum 308 (FIGS. 19-20)having a porous surface, such as a Vyon sheet having a plurality ofsmall pores (e.g., a pore size of 50-90 microns). The vacuum plenum 308is divided into two or more (e.g., three) vacuum zones 310 (FIGS. 20-23)that are shaped complementary to the shape of the prepreg segments 150,as cut by the cutting station 230. The vacuum plenum 308 includes arigid plenum frame 312 to support the vacuum plenum 308. As shown inFIG. 18, the plenum frame 312 is configured to be attached to therobotic arm 304 via a plenum adapter fitting 314. Each one of the vacuumzones 310 (FIGS. 19-20) of the vacuum plenum 308 is fluidically coupledto a vacuum source such as a compressed air-powered vacuum generator, orto central shop vacuum. The vacuum zones 310 are independentlyactivatable with vacuum pressure to allow the vacuum end effector 306 toengage with different shapes of the prepreg segment 150.

In the example vacuum end effector 306 of FIGS. 21-23, the vacuum plenum308 includes vacuum zone A, vacuum zone B, and vacuum zone C, and whichare shaped and configured specific to a situation where the width of theunidirectional prepreg 122 (i.e., the input material) is equivalent tothe width of the backed cross-ply prepreg 416 (i.e., the outputmaterial). For example, the width of the unidirectional prepreg 122 maybe 6 inches, and the width of the backed cross-ply prepreg 416 may alsobe 6 inches. However, for examples where the width of the unidirectionalprepreg 122 (e.g., 12 inches) is different than the width of the backedcross-ply prepreg 416 (e.g., 6 inches), the vacuum zones would be shapeddifferently than the vacuum zones shown in FIGS. 21-23.

FIG. 21 illustrates a −90-degree prepreg segment 160, and the activationof vacuum zones A and B for vacuum coupling the vacuum end effector 306to the 90-degree prepreg segment 160. FIG. 22 illustrates a −45-degreeprepreg segment 162, and the activation of vacuum zones B and C forvacuum coupling the vacuum end effector 306 to the −45-degree prepregsegment 162. FIG. 23 illustrates a +45-degree prepreg segment 164, andthe reorientation of the vacuum end effector 306 for vacuum coupling ofthe vacuum end effector 306 to the +45-degree prepreg segment 164.

FIG. 24 shows a −45-degree prepreg segment 162 at the segment pickuplocation 286 of the cutting machine 110. FIG. 25 shows the robotic arm304 positioning the vacuum end effector 306 over the −45-degree prepregsegment 162 for vacuum engagement. FIG. 26 shows the robotic arm 304re-orienting the −45-degree prepreg segment 162, and placing the−45-degree prepreg segment 162 on the conveyor belt 418 such that thesegment cut edges 152 are parallel to the lengthwise direction of theconveyor belt 418. FIG. 27 shows the −45-degree prepreg segment 162 onthe conveyor belt 418 after release from the vacuum end effector 306.

In the example of the manufacturing system 100, the conveyor belt 418 isconfigured to move at a constant speed, and the pick-and-place system300 (e.g., the robotic arm 304) is configured to match the speed of theconveyor belt 418 when placing a prepreg segment 150 on the conveyorbelt 418. In this regard, the speed at which the manufacturing system100 produces backed cross-ply prepreg 416 is dictated by the speed ofthe conveyor belt 418, which may be independently driven and controlledusing a manufacturer-provided drive and controller.

In the example shown, the conveyor belt 418 is a vacuum conveyor beltconfigured to be fluidically coupled to a vacuum source (not shown) fornon-movably securing the prepreg segments 150 to the vacuum conveyorbelt upon placement by the pick-and-place system 300. In this regard,the target for placement of the first prepreg segment 156 on theconveyor belt 418 may be nominally set to a global x,y coordinatelocation on the conveyor belt 418. Once the first prepreg segment 156 isplaced on the conveyor belt 418, the conveyor belt 418 begins motion,and the pick-and-place system 300 continuously places prepreg segments150 in end-to-end relation on the moving conveyor belt 418. The conveyorbelt 418 may include a rotary encoder mounted to a conveyor belt shaft(not shown) for determining when the prepreg segments 150 has moved anappropriate distance to allow placement of the next prepreg segment 150.The robotic device 302 may be programmed to follow the conveyor belt 418for a short distance in order to match the speed of the conveyor belt418. Once the speed is matched, the end effector places the prepregsegment 150 on the conveyor belt 418, and vacuum pressure is disengagedfrom the vacuum end effector 306, thereby transferring the prepregsegment 150 to the conveyor belt 418.

Although not shown, the manufacturing system 100 may further include avision system for increasing the accuracy of pickup and placement of theprepreg segments 150. The vision system may include an imaging device(e.g., a camera) configured to image each prepreg segment 150 at thesegment pickup location 286, and transmit to the controller 102, theactual location (e.g., in x,y coordinates) and orientation (e.g., inangular degrees) relative to the nominal location and nominalorientation of the prepreg segment 150 at the segment pickup location286. The controller 102 is configured to control the robotic device 302in a manner to compensate for the difference between the actuallocation/orientation and the nominal location/orientation, to betteralign the end effector to the prepreg segment 150 at the segment pickuplocation 286. In this same regard, the vision system may facilitateincreased accuracy of the pick-and-place system 300 in placing eachprepreg segment 150 on the conveyor belt 418. The vision system may bemounted at any one of a variety of locations on the manufacturing system100. For example, the vision system may be mounted on the robotic arm304, on the end effector, on the cutting machine 110 at a location aboveand/or below the segment pickup location 286, and/or on the adhesionmachine 400 above the location where the prepreg segments 150 are placedon the conveyor belt 418.

Referring now to FIGS. 28-33, shown is an example of the adhesionmachine 400. As mentioned above, the adhesion machine 400 is configuredto sequentially adhere the prepreg segments 150 to the backing material404 in a manner transferring the prepreg segments 150 from the conveyorbelt 418 to the backing material 404. In this regard, the adhesion forcebetween the prepreg segments 150 in the backing material 404 is greaterthan the vacuum force coupling the prepreg segments 150 to the conveyorbelt 418, resulting in each prepreg segment 150 gradually adhering tothe backing material 404 while gradually releasing from vacuumengagement with the conveyor belt 418, and thereby resulting in thecontinuous length of backed cross-ply prepreg 416. The adhesion machine400 is configured to wind the backed cross-ply material onto a cross-plymaterial collection drum 412 at a specified tension, as described ingreater detail below.

Referring to FIGS. 28-29 and 33, the adhesion machine 400 includes abacking material chuck 410 configured to support a backing material drum408. The backing material drum 408 supports a roll of the backingmaterial 404. The backing material 404 is spooled off of the backingmaterial drum 408, and is fed through the adhesion machine 400 at thesame speed as the conveyor belt 418. The adhesion machine 400 furtherincludes a cross-ply material collection chuck 414 configured to supporta cross-ply material collection drum 412. The cross-ply materialcollection drum 412 is configured to collect the backed cross-plyprepreg 416 resulting from the adhesion of the prepreg segments 150 tothe backing material 404. The backing material chuck 410 and thecross-ply material collection chuck 414 each have a chuck servomotor 118(FIG. 1) for rotatably driving the backing material chuck 410 and thecross-ply material collection chuck 414.

Referring to FIG. 31, the adhesion machine 400 may include at least oneidler roller 182 for redirecting the backing material 404 as it isspooled off of the backing material drum 408. Although not shown, theidler roller 182 may include a pair of circumferential alignment ridgesspaced apart by a distance equivalent to the width of the backingmaterial 404. As mentioned above with regard to the rollers of thecutting machine 110, the circumferential alignment ridges on the idlerroller 182 of the adhesion machine 400 provide a means for maintainingthe alignment of the backing material 404 with the prepreg segments 150on the conveyor belt 418, thereby preventing the prepreg segments 150from overhanging the edges of the backing material 404.

Referring to FIGS. 30-32, the manufacturing system 100 includes at leastone compaction stage 425 configured to compact the backing material 404against the prepreg segments 150 for transferring the prepreg segments150 to the backing material 404. For example, FIG. 32 shows an initialcompaction stage 426 and a secondary compaction stage 430, each of whichis configured to apply compaction pressure to the prepreg segments 150against the backing material 404. In FIG. 31-32, several of thestructural supports (e.g., see FIGS. 28-30) on one side of the initialcompaction stage 426 and the secondary compaction stage 430 have beenremoved to better illustrate the components of the compaction stages426, 430.

In FIGS. 30-32, the initial compaction stage 426 is located upstream ofa downstream end of the conveyor belt 418. The initial compaction stage426 has an initial compaction roller 428 configured to apply an initialcompaction pressure to the backing material 404 against the prepregsegments 150 on the conveyor belt 418. The initial compaction stage 426includes a pair of compaction actuators 438 (e.g., linear pneumaticactuators) located respectively on opposing ends of the initialcompaction roller 428, for vertically applying compaction pressure ofthe initial compaction roller 428 against the prepreg segments 150supported on the conveyor belt 418.

Referring to FIG. 32, the secondary compaction stage 430 is locateddownstream of the downstream end of the conveyor belt 418. The secondarycompaction stage 430 has an upper compaction roller 432 and a lowercompaction roller 434 vertically positioned relative to each other todefine a roller interface 210. The vertical positioning of the uppercompaction roller 432 relative to the lower compaction roller 434negates the possibility of a horizontal force that may induce ahorizontal component that would otherwise cause slipping at theinterface between the prepreg segments 150 and the backing material 404.

The secondary compaction stage 430 includes a pair of compactionactuator 438 (e.g., linear pneumatic actuators) located respectively onopposing ends of the upper compaction roller 432, for vertically movingthe upper compaction roller 432 toward and away from the lowercompaction roller 434 for adjusting the size of the gap at the rollerinterface 210. The roller interface 210 receives the backed cross-plyprepreg 416 from the initial compaction stage 426, and applies asecondary compaction pressure of the prepreg segments 150 against thebacking material 404 in a manner that increases the adhesion of theprepreg segments 150 to the backing material 404. The initial compactionroller 428 of the initial compaction stage 426, and the upper and lowercompaction rollers 432, 434 of the secondary compaction stage 430 mayhave an outer surface formed of elastomeric material such as rubber(e.g., EPDM) to accommodate the potential non-uniform application ofcompaction force, and may thereby avoid damaging the prepreg segments150 during compaction against the backing material 404.

Advantageously, the initial compaction stage 426 and the secondarycompaction stage 430 provide two separate locations where the prepregsegments 150 are compacted against the backing material 404. In thisregard, the two separate compaction stages 425 double the dwell timeduring which the prepreg segments 150 and backing material 404 are undercompaction, thereby reducing the need for excessive compaction at anyone of the compaction stages, and correspondingly reducing the potentialfor damage to the prepreg material. Furthermore, locating the secondarycompaction stage 430 downstream of the conveyor belt 418 addresses thepotential for the prepreg segments 150 to lose adhesion from the backingmaterial 404 after the prepreg segments 150 release from the vacuum ofthe conveyor belt 418. In this regard, the secondary compaction stage430 ensures that the prepreg segments 150 remain adhered to the backingmaterial 404 as the backed cross-ply prepreg 416 is wound onto thecross-ply material collection drum 412. In addition, two separatecompacting stages 425 provide a means for varying the compactionpressure applied at the initial compaction stage 426 and the secondarycompaction stage 430. In this regard, the magnitude of the initialcompaction force applied by the initial compaction roller 428 may belimited as a result of deflection of the structure of the conveyor belt418. In such case, the secondary compaction stage 430 may apply anincreased amount of compaction pressure to compensate for reducedcompaction pressure at the initial compaction stage 426.

In FIG. 32, the lower compaction roller 434 is rotatably driven by acompaction roller servomotor 436 (FIG. 1) for pulling the backingmaterial 404 through the adhesion station 420. The compaction rollerservomotor 436 sets the speed at which the backing material 404 is drawnthrough the adhesion machine 400, which is equivalent to the speed ofthe conveyor belt 418, to thereby negate the potential for slippage atthe interface between the prepreg segments 150 and the backing material404, which may otherwise compromise the quality of the backed cross-plyprepreg 416. Although not shown, the backing material chuck 410 mayinclude a brake that is configured to halt rotation of the backingmaterial drum 408 if the secondary compaction stage 430 ceases to pullthe backing material 404 through the adhesion station 420.

Referring to FIGS. 28-30, the adhesion machine 400 further include oneor more heating devices 440 configured to heat the backing material 404and/or the prepreg segments 150, as a means for increasing the adhesionof the prepreg segments 150 to the backing material 404. In the exampleshown, the adhesion machine 400 includes one or more heating devices 440supported on a heating device support frame 444. The heating devices 440are located above the conveyor belt 418 and upstream of the adhesionstation 420. The heating devices 440 are configured to heat the prepregsegments 150 as a means to increase the tack of the resin in the prepregsegments 150 and/or slightly reduce the resin viscosity, all of whichfacilitates adhesion to the backing material 404.

In one example, the heating devices 440 are infrared emitters 442configured as infrared heater bulbs. The infrared emitters 442 arelocated at a spaced distance away from the prepreg segments 150 and thebacking material 404, to thereby avoid contamination that wouldotherwise occur using heating devices that require direct contact withthe prepreg segments 150 or the backing material 404. Advantageously,infrared emitters 442 allow for precise control of the heat applied tothe prepreg segments 150 and backing material 404 to avoid damage to theprepreg segments 150 or the backing material 404. Furthermore, infraredheaters allow for focusing heat accurately on the surfaces toward whichthey are aimed, thereby avoiding the heating of nearby components thatmay result in adverse effects, such as excessive resin buildup onindirectly heated components. In the example shown, the adhesion machine400 includes a first ceramic infrared heater facing downwardly towardthe prepreg segments 150 on the conveyor belt 418, and a second ceramicinfrared heater facing horizontally toward the backing material 404prior to contact with the prepreg segments 150 on the conveyor belt 418.

Referring to FIGS. 30-31 and 33, the adhesion machine 400 includes atleast one tension-measuring device 422 configured to measure tensionload in the backing material 404 and/or in the backed cross-ply prepreg416. In the example shown, the tension-measuring devices 422 eachcomprise a cantilevered load cell 424 which has a cylindrical surfaceconfigured to measure tension load based on a side force applied to thecylindrical surface. For example, as shown in FIGS. 29-31, the adhesionmachine 400 includes a load cell 424 between the idler roller 182 andthe first compaction roller for measuring tension in the backingmaterial 404, after spooling off of the backing material drum 408 andprior to making contact with the prepreg segments 150. FIGS. 28-29, 31,and 33 show a load cell 424 between the secondary compaction stage 430and the cross-ply material collection drum 412 for measuring tension inthe backed cross-ply prepreg 416 prior to winding onto the cross-plymaterial collection drum 412.

Each load cell 424 is configured to transmit tension measurements to acontroller 102, which uses the tension measurements to control thetorque load of the drums, as a means for maintaining tension load in thebacking material 404 and in the backed cross-ply prepreg 416 withinpredetermined ranges. For example, the controller 102 uses the tensionmeasurements from the load cell 424 between the idler roller 182 and thefirst compaction roller, to control the chuck servomotor 118 of thebacking material chuck 410 to adjust the torque load on the backingmaterial drum 408 in a manner maintaining the tension load on thebacking material 404 within a predetermined load range. The controller102 uses the tension measurements from the load cell 424 between thesecondary compaction stage 430 and the backed cross-ply materialcollection drum 412 to control the chuck servomotor 118 of the cross-plymaterial collection chuck 414 to adjust the torque load on the cross-plymaterial collection drum 412 in a manner maintaining the tension load onthe backed cross-ply prepreg 416 within a predetermined load range(e.g., 25-30 pounds of force).

Referring to FIG. 34, shown is a flowchart of operations included in amethod 500 of manufacturing a roll of a continuous length of a backedcross-ply prepreg 416. The method 500 includes supporting a firstcontinuous length of unidirectional prepreg 128 (e.g., unidirectionalprepreg tape) on a backed unidirectional prepreg drum 114. As mentionedabove, the first continuous length of unidirectional prepreg 128 isbacked by a backing layer 126 such as a backing paper or a polymericfilm. The method includes separating the backing layer 126 from thefirst continuous length of unidirectional prepreg 128 while feeding theunidirectional prepreg 128 into the cutting station 230. In addition,the method includes collecting, on the backing layer collection drum132, the backing layer 126 as the backing layer 126 is peeled off of thefirst continuous length of unidirectional prepreg 128.

The method 500 further comprises receiving the unidirectional prepreg128 within a roller interface 210 of opposing nip rollers 202 of a niproller assembly 200, and feeding, using the nip rollers 202, alengthwise section of the unidirectional prepreg 128 into the cuttingstation 230 of the cutting machine 110. As mentioned above, the niproller assembly 200 has an upper nip roller 204 and a lower nip roller206 defining the roller interface 210. The upper nip roller 204 ismovable, via a nip roller actuator 212, to adjust the gap of the rollerinterface 210 for receiving and clamping onto the unidirectional prepreg128. The nip roller servomotor 208 rotatably drives the lower nip roller206, causing the predetermined length of the unidirectional prepreg 128to be fed into the cutting station 230 for cutting into a prepregsegment 150. The method 500 further comprises applying a substantiallyconstant tension load on the unidirectional prepreg 128 as the niproller assembly 200 feeds the unidirectional prepreg 128 into thecutting station 230. The substantially constant tension load in theunidirectional prepreg 128 is controlled by the pneumatic dancerassembly 180, which is located between the backed unidirectional prepregdrum 114 and the nip roller assembly 200.

As shown in FIGS. 8-9 and described above, the backing layer collectiondrum 132 may optionally be located proximate the cutting station 230, incontrast to the arrangement shown in FIGS. 1-5 in which the backinglayer collection drum 132 is located immediately adjacent to the backedunidirectional prepreg drum 114. In FIGS. 8-9, the step of separatingthe backing layer 126 from the first continuous length of unidirectionalprepreg 128 comprises, separating the backing layer 126 from theunidirectional prepreg 128 as the unidirectional prepreg 128 exits thenip roller assembly 200 prior to entering the cutting station 230. Thebacking layer 126 is collected on the backing layer collection drum 132,which is located downstream of the nip roller assembly 200 and upstreamof the cutting station 230. As mentioned above, the arrangement shown inFIGS. 8-9 improves the stability and accuracy with which theunidirectional prepreg 128 is controlled while passing through thecutting machine 110.

Step 502 of the method 500 includes cutting, using the cutting station230, the first continuous length of the unidirectional prepreg 128 intofirst prepreg segments 156. Each one of the first prepreg segments 156has an opposing pair of segment cut edges 152 that are non-parallel tothe lengthwise direction of the unidirectional prepreg 122. Step 502 ofcutting the unidirectional prepreg 128 comprises cutting theunidirectional prepreg 128 such that the segment cut edges 152 areoriented at +45 degrees, −45 degrees, 90 degrees, or other angles,relative to the lengthwise direction of the unidirectional prepreg 128.Toward this end, step 502 of cutting the unidirectional prepreg 128comprises locking, via a turntable 242 of the cutting station 230, theorientation of the cutting device 236 (e.g., a cutting wheel, anultrasonic device) relative to the lengthwise direction of theunidirectional prepreg 128. As described above, the turntable 242 hasdetents 244 for locking the orientation of the cutting device 236. Step502 further includes translating the cutting device 236 across a widthof the unidirectional prepreg 128 to cut the unidirectional prepreg 128into the prepreg segments 150. In the example shown, the cuttingassembly 232 includes a cutting device actuator 240 configured as apneumatic air slide for translating the cutting device 236 across thewidth of the unidirectional prepreg 128.

Step 502 of cutting the first continuous length of unidirectionalprepreg 128 additionally comprises securing, via vacuum pressure, theunidirectional prepreg 128 to the cutting surface 250 of the cuttingstation 230. As described above, the cutting surface 250 is porous orhas a plurality of pores that are fluidically coupled to a vacuumsource. Each time the nip roller assembly 200 extends a predeterminedlength of unidirectional prepreg 128 into the cutting station 230, thevacuum source is activated to vacuum couple the prepreg to the cuttingsurface 250 for securing the unidirectional prepreg 128 in positionduring cutting by the cutting device 236.

The method includes using the prepreg clamps 274 to clamp onto opposingsides of the unidirectional prepreg 128, and apply tension to theunidirectional prepreg 128 via the clamp transporter actuator 280 (e.g.,a linear pneumatic actuator) of the segment delivery system 270. Oncetension is applied, vacuum pressure is then applied to the cuttingsurface 250 to secure the unidirectional prepreg 128 to the cuttingsurface 250, after which the clamp transporter actuator 280 isdeactivated to halt the application of tension on the unidirectionalprepreg 128. The cutting device 236 is then driven across theunidirectional prepreg 128 to result in a prepreg segment 150. Aftercutting the unidirectional prepreg 128, the prepreg clamps 274 remainclamped onto the prepreg segment 150, and vacuum pressure is deactivatedat the cutting surface 250 to allow the prepreg segment 150 to betranslated off of the cutting surface 250. In some examples, the cuttingsurface 250 may discharge compressed air from the pores or poroussurface of the cutting surface 250, to urge the prepreg segment 150 awayfrom the cutting surface 250, and promote the sliding translation of theprepreg segment 150 off of the cutting surface 250.

The method 500 further comprises transporting, using the segmentdelivery system 270, each prepreg segment 150 from the cutting surface250 to the segment pickup location 286 for pickup by the pick-and-placesystem 300. As described above, the segment delivery system 270 islocated immediately downstream of the cutting surface 250. Transportingeach prepreg segment 150 comprises moving, via the clamp transporteractuator 280, the prepreg clamps 274 along a pair of linear guide rails278, to thereby transport each prepreg segment 150 to the segment pickuplocation 286. Upon arrival at the segment pickup location 286, vacuumpressure is applied to the delivery system vacuum table 284 to securethe prepreg segment 150 in position at the segment pickup location 286,and the prepreg clamps 274 are then moved to the unclamped position. Theclamp transporter actuator 280 then translates the prepreg clamps 274back to the delivery system support table 282 in preparation forclamping another downstream portion of unidirectional prepreg 128 thatis fed into the cutting station 230 by the nip roller assembly 200.

Step 504 of the method 500 includes sequentially picking up, using thepick-and-place system 300, the first prepreg segments 156 at the segmentpickup location 286, and placing the first prepreg segments 156 inend-to-end relation onto the conveyor belt 418, and in an orientationsuch that the segment cut edges 152 are generally parallel to alengthwise direction of the conveyor belt 418. In the example shown inthe figures, step 504 of picking up the first prepreg segments 156comprises picking up each prepreg segment 150 using a robotic arm 304 ofa robotic device 302. However, in other examples not shown, the prepregsegments 150 may be picked up by an overhead gantry system, or othermechanisms capable of transferring the prepreg segments 150 from thecutting machine 110 to the adhesion machine 400.

In the example shown, step 504 of picking up the first prepreg segments156 comprises vacuum coupling, using a vacuum plenum 308, each prepregsegment 150 to the robotic arm 304. As described above, the vacuumplenum 308 has a porous surface coupled to a vacuum source. Vacuumcoupling of each prepreg segment 150 to the robotic arm 304 comprisespositioning the vacuum plenum 308 over the prepreg segment 150 at thesegment pickup location 286, and applying vacuum pressure to one or morevacuum zones 310, based on the shape of the prepreg segment 150. In theabove-described example of FIGS. 21-23, the vacuum plenum 308 includesvacuum zones A, B, and C. As described above, each one of the vacuumzones 310 is independently fluidically coupled to a vacuum source, toenable independently providing vacuum pressure to any combination ofvacuum zones 310 to enable vacuum engagement to different shapes of theprepreg segment 150.

To facilitate alignment of the vacuum end effector 306 with the prepregsegment 150 prior to pickup, the method 500 may include imaging, using avision system (e.g., a camera—not shown), each prepreg segment 150 atthe segment pickup location 286, and indexing the robotic arm 304 to theprepreg segment 150 based on the imaging, as described above. As analternative to mounting on the robotic arm 304, the vision system may bemounted to the cutting machine 110 at a location above and/or below thesegment pickup location 286. Additionally, a vision system (e.g., acamera) may be mounted to the adhesion machine 400 above the locationwhere the prepreg segments 150 are placed on the conveyor belt 418.

Step 506 of the method 500 includes feeding, using the conveyor belt418, the first prepreg segments 156 to the adhesion station 420 of theadhesion machine 400. As mentioned above, step 506 of feeding the firstprepreg segments 156 to the adhesion station 420 comprises moving theconveyor belt 418 at a constant speed, and matching the speed of thepick-and-place system 300 (e.g., the vacuum end effector 306) to thespeed of the conveyor belt 418 when placing a prepreg segment 150 on theconveyor belt 418. To prevent movement of the prepreg segments 150 onceplaced on the conveyor belt 418, step 506 of feeding the first prepregsegments 156 to the adhesion station 420 comprises vacuum coupling thefirst prepreg segments 156 to a vacuum conveyor belt.

Step 508 of the method 500 includes sequentially adhering, using theadhesion station 420, the first prepreg segments 156 to a continuouslength of a backing material 404. Vacuum coupling of the first prepregsegments 156 to the conveyor belt 418 may prevent movement of the firstprepreg segments 156 when being adhered to the backing material 404.Step 508 of adhering the first prepreg segments 156 includes spoolingthe backing material 404 off of the backing material drum 408, andfeeding the backing material 404 over the conveyor belt 418. As thebacking material 404 is spooled off of the backing material drum 408 andthe prepreg segments 150 are adhered to the backing material 404, themethod includes collecting the resulting backed cross-ply prepreg 416onto the cross-ply material collection drum 412. As described above, thebacking material drum 408, and the cross-ply material collection drum412 are each rotatably driven by a chuck servomotor 118.

Step 508 of adhering the first prepreg segments 156 to the backingmaterial 404 comprises compacting, using at least one compaction stage425, the backing material 404 against the prepreg segments 150 in such amanner causing the prepreg segments 150 to adhere to the backingmaterial 404, and resulting in a continuous length of backed cross-plyprepreg 416. In the example shown, compacting the backing material 404against the prepreg segments 150 comprises applying an initialcompaction pressure to the backing material 404 against the prepregsegments 150 supported on the conveyor belt 418. The initial compactionpressure is applied using an initial compaction roller 428 at an initialcompaction stage 426 located upstream of the downstream end of theconveyor belt 418. Following the application of the initial compactionpressure, the method additionally includes applying a secondarycompaction pressure of the backing material 404 and the prepreg segments150 against each other. The secondary compaction pressure is applied onthe backed cross-ply prepreg 416 which his sandwiched between an uppercompaction roller 432 and a lower compaction roller 434 at a secondarycompaction stage 430 located downstream of the downstream end of theconveyor belt 418, as described above.

The method 500 further includes rotatably driving the upper compactionroller 432 and/or the lower compaction roller 434 to pull the backingmaterial 404 through the adhesion station 420. As a safety precaution,method 500 may comprise halting, using a brake of the backing materialchuck 410, rotation of the backing material drum 408 if the secondarycompaction stage 430 ceases to pull the backing material 404 through theadhesion station 420. In the example shown, the lower compaction roller434 is rotatably driven by a compaction roller servomotor 436 configuredto pull the backing material 404 through the adhesion station 420 at thesame speed as the conveyor belt 418. By applying compaction pressure attwo separate compaction stages, the total amount of dwell time duringwhich the prepreg segments 150 and backing material 404 are undercompaction is doubled, relative to configurations (not shown) where asingle compaction stage is relied upon to compact the prepreg segments150 against the backing material 404.

To facilitate adhesion of the prepreg segments 150 to the backingmaterial 404, the method 500 further comprises heating, using at leastone heating device 440, the backing material 404 and/or the prepregsegments 150 prior to compaction. Heating the backing material 404 isperformed using one or more heating devices 440 located above theconveyor belt 418. In one example, heating the backing material 404 mayinclude heating the backing material 404 using one or more infraredemitters 442. For example, a first ceramic infrared heater may facedownwardly toward the prepreg segments 150 on the conveyor belt 418. Asecond ceramic infrared heater may face horizontally toward the backingmaterial 404 prior to contact with the prepreg segments 150 on theconveyor belt 418.

The method 500 further comprises measuring, using at least onetension-measuring device 422, tension load in the backing material 404and/or tension load in the backed cross-ply prepreg 416. For example,tension load in the backing material 404 may be measured using a loadcell 424 having a cylindrical outer surface configured to bear againstthe backing material 404 as it spools off of the backing material drum408 prior to contacting the prepreg segments 150. Tension load in thebacked cross-ply prepreg 416 may be measured using a similar load cell424 located between the secondary compaction stage 430 and the cross-plymaterial collection drum 412. Advantageously, the tension-measuringdevices 422 allow the controller 102 to control the chuck servomotors118 to adjust the amount of torque load on the backing material drum 408and the cross-ply material collection drum 412, as a means to maintainthe tension load within predetermined limits.

Referring to FIGS. 35-49, shown are schematic illustrations of theprocesses for manufacturing different orientation combinations of thebacked cross-ply prepreg 416. FIGS. 35-37 represent the processes formanufacturing 3 different orientations of a backed cross-ply prepreg 416that has a single layer of prepreg material supported on a backing layer126 (i.e., a single layer of cross-directional prepreg material on abacking layer 126). FIGS. 38-49 represent the processes formanufacturing 12 different orientations of a backed cross-ply prepreg416 that has two layers of prepreg material supported on a backing layer126, and in which at least one of the layers of prepreg materialcomprises a cross-directional prepreg material (i.e., the reinforcingfibers are non-parallel to the lengthwise direction of the backedcross-ply prepreg 416).

In FIGS. 35-37, each of the 3 processes involves the above-describedsteps 502, 504, and 506. Step 508 of the process comprises adhering thefirst prepreg segments 156 to a continuous length of a backing layer 126that is devoid of prepreg material. FIG. 35 shows prepreg segments 150being cut from the first continuous length of unidirectional prepreg 128via the cutting machine 110, re-oriented via the pick-and-place system300, and placed on the adhesion machine 400 as 90-degree prepregsegments 160, after which compaction pressure is applied by one or morecompaction stages 425 for adhering the 90-degree prepreg segments 160 tothe backing layer 126, and resulting in a 90-degree backed prepreg 450.FIG. 36 shows −45-degree prepreg segments 162 being cut from a firstcontinuous length of unidirectional prepreg 128, re-oriented and placedon the adhesion machine 400, and then adhered via the compaction stagesto a backing layer 126, and resulting in a −45-degree backed prepreg452. FIG. 37 shows +45-degree prepreg segments 164 being cut from afirst continuous length of unidirectional prepreg 128, re-oriented andplaced on the adhesion machine 400, and then adhered via the compactionstages to a backing layer 126, and resulting in a +45-degree backedprepreg 454.

Referring to FIGS. 38-49, each of the 12 respectively representedprocesses involves the above-described steps 502, 504, and 506. FIGS.38-40 represent processes in which step 508 comprises adhering, usingthe adhesion station 420, the first prepreg segments 156 to a continuouslength of a prepreg-backing assembly 406, which comprises prepregmaterial backed by a backing layer 126. FIG. 38 shows prepreg segments150 being cut from a first continuous length of unidirectional prepreg128 via the cutting machine 110, re-oriented via the pick-and-placesystem 300, and placed on the conveyor belt 418 of the adhesion machine400 as 90-degree prepreg segments 160, after which compaction pressureis applied by one or more compactions stages 425 for adhering the90-degree prepreg segments 160 to a second continuous length of aunidirectional prepreg 130 (i.e., 0-degree prepreg) backed by a backinglayer 126, and resulting in a 0/90-degree backed prepreg 456, whereinthe 0-degree prepreg is sandwiched between the backing layer 126 and the90-degree prepreg. FIG. 39 shows −45-degree prepreg segments 162 beingcut from a first continuous length of unidirectional prepreg 128,re-oriented and placed on the conveyor belt 418, and then adhered viathe compaction stages to a second continuous length of a unidirectionalprepreg 130 backed by a backing layer 126, and resulting in a0/−45-degree backed prepreg 458, wherein the 0-degree prepreg issandwiched between the backing layer 126 and the −45-degree prepreg.FIG. 40 shows +45-degree prepreg segments 164 being cut from a firstcontinuous length of unidirectional prepreg 128, and adhered to a secondcontinuous length of a unidirectional prepreg 130 backed by a backinglayer 126, and resulting in a 0/+45-degree backed prepreg 460, whereinthe 0-degree prepreg is sandwiched between the backing layer 126 and the+45-degree prepreg.

FIGS. 41-46 represent processes in which step 508 comprises adhering,using the adhesion station 420, the first prepreg segments 156 to acontinuous length of a prepreg-backing assembly 406, which comprises abacked cross-ply prepreg 416 (i.e., an intermediate backed cross-plyprepreg 480) previously manufactured by the manufacturing system 100.The backed cross-ply prepreg 416 to which the first prepreg segments 156are adhered comprises a series of second prepreg segments 158 on abacking layer 126. In this regard, FIGS. 41-46 represent processes forwhich a series of first prepreg segments 156 are adhered to a series ofsecond prepreg segments 158 of a previously-manufactured backedcross-ply prepreg 416, to result in a final backed cross-ply prepreg482. In each example, the fiber angles of the first prepreg segments 156are non-parallel to the fiber angles of the second prepreg segments 158.

FIG. 41 shows 90-degree prepreg segments 160 being cut from a firstcontinuous length of unidirectional prepreg 128, re-oriented, andadhered to a series of −45-degree prepreg segments 162 backed by abacking layer 126 (i.e., the intermediate backed cross-ply prepreg 480),and resulting in a −45/90-degree backed prepreg 462 (i.e., the finalbacked cross-ply prepreg 482), wherein the −45-degree prepreg issandwiched between the backing layer 126 and the 90-degree prepreg. FIG.42 shows −45-degree prepreg segments 162 being cut from a firstcontinuous length of unidirectional prepreg 128, and adhered to a seriesof 90-degree prepreg segments 160 backed by a backing layer 126, andresulting in a 90/−45-degree backed prepreg 464, wherein the 90-degreeprepreg is sandwiched between the backing layer 126 and the −45-degreeprepreg. FIG. 43 shows −45-degree prepreg segments 162 being cut from afirst continuous length of unidirectional prepreg 128, and adhered to aseries of +45-degree prepreg segments 164 backed by a backing layer 126,and resulting in a +45/−45-degree backed prepreg 466, wherein the+45-degree prepreg is sandwiched between the backing layer 126 and the−45-degree prepreg.

FIG. 44 shows +45-degree prepreg segments 164 being cut from a firstcontinuous length of unidirectional prepreg 128, and adhered to a seriesof −45-degree prepreg segments 162 backed by a backing layer 126 (i.e.,the intermediate backed cross-ply prepreg 480), and resulting in a−45/+45-degree backed prepreg 468 (i.e., the final backed cross-plyprepreg 482), wherein the −45-degree prepreg is sandwiched between thebacking layer 126 and the +45-degree prepreg. FIG. 45 shows +45-degreeprepreg segments 164 being cut from a first continuous length ofunidirectional prepreg 128, and adhered to a series of 90-degree prepregsegments 160 backed by a backing layer 126, and resulting in a90/+45-degree backed prepreg 470, wherein the 90-degree prepreg issandwiched between the backing layer 126 and the +45-degree prepreg.FIG. 46 shows 90-degree prepreg segments 160 being cut from a firstcontinuous length of unidirectional prepreg 128, and adhered to thecontinuous length of a series of +45-degree prepreg segments 164 backedby a backing layer 126, and resulting in a +45/90-degree backed prepreg472, wherein the +45-degree prepreg is sandwiched between the backinglayer 126 and the 90-degree prepreg.

FIGS. 47-49 represent processes in which, after performing step 508 ofadhering the first prepreg segments 156 to a continuous length ofbacking material 404 devoid of other prepreg material, the method 500further comprises feeding a second continuous length of unidirectionalprepreg 130 to the adhesion station 420, and adhering the secondcontinuous length of unidirectional prepreg 130 to the first prepregsegments 156 on the continuous length of backing material 404 (i.e., theintermediate backed cross-ply prepreg 480). The second continuous lengthof unidirectional prepreg 130 is fed through the cutting station 230(without cutting), and into the adhesion station 420. Manufacturing theorientation combinations that are shown in FIGS. 47-49 requires that thecutting machine 110 is aligned with the adhesion machine 400, as shownin FIGS. 1-3. In this regard, the direction of movement of the secondcontinuous length of unidirectional prepreg 130 through the cuttingmachine 110 is aligned with the direction of movement of the conveyorbelt 418.

The processes represented by FIGS. 47-49 require mounting, on theadhesion machine 400, a roll of backed cross-ply prepreg comprising thefirst prepreg segments 156 on a backing layer 126 (i.e., an intermediatebacked cross-ply prepreg 480). In addition, the processes requiremounting, on the cutting machine 110, a roll of a second continuouslength of unidirectional prepreg 130, and drawing the second continuouslength of unidirectional prepreg 130 through the cutting machine 110,without cutting into prepreg segments 150. Instead, the processes ofFIGS. 47-49 include feeding, using the conveyor belt 418, the secondcontinuous length of unidirectional prepreg 130 onto the conveyor belt418 of the adhesion station 420, while drawing over the conveyor belt418, the continuous length of the first prepreg segments 156 on thebacking layer 126. The processes also include adhering the secondcontinuous length of unidirectional prepreg 130 to the continuous lengthof the first prepreg segments 156 on the backing layer 126, therebyresulting in two layers of prepreg segments 150 on the backing layer 126(i.e., the final backed cross-ply prepreg 482).

FIG. 47 shows a second continuous length of unidirectional prepreg 130(i.e., 0-degree prepreg) being adhered to a continuous length of abacked cross-ply prepreg 416 comprising a series of 90-degree prepregsegments 160 backed by a backing layer 126, and resulting in a90/0-degree backed prepreg 474, wherein the 90-degree prepreg issandwiched between the backing layer 126 and the 0-degree prepreg. FIG.48 shows a second continuous length of unidirectional prepreg 130 beingadhered to a continuous length of a backed cross-ply prepreg 416comprising a series of −45-degree prepreg segments 162 backed by abacking layer 126, and resulting in a −45/0-degree backed prepreg 476,wherein the −45-degree prepreg is sandwiched between the backing layer126 and the 0-degree prepreg. FIG. 49 shows a second continuous lengthof unidirectional prepreg 130 being adhered to a continuous length of abacked cross-ply prepreg 416 comprising a series of +45-degree prepregsegments 164 backed by a backing layer 126, and resulting in a+45/0-degree backed prepreg 478, wherein the +45-degree prepreg issandwiched between the backing layer 126 and the 0-degree prepreg.

Additional modifications and improvements of the present disclosure maybe apparent to those of ordinary skill in the art. Thus, the particularcombination of parts described and illustrated herein is intended torepresent only certain examples of the present disclosure and is notintended to serve as limitations of alternative examples or deviceswithin the spirit and scope of the disclosure.

What is claimed is:
 1. A manufacturing system for manufacturing a backedcross-ply prepreg, comprising: a cutting machine having a cuttingstation configured to cut a continuous length of a unidirectionalprepreg into prepreg segments, each having an opposing pair of segmentcut edges that are non-parallel to a lengthwise direction of theunidirectional prepreg; an adhesion machine having a conveyor belt andan adhesion station; a pick-and-place system configured to pick up theprepreg segments from the cutting machine, and place the prepregsegments in end-to-end relation on the conveyor belt, and in anorientation such that the segment cut edges are generally parallel to alengthwise direction of the conveyor belt; and wherein the conveyor beltis configured to feed the prepreg segments to the adhesion station, theadhesion station configured to adhere the prepreg segments to acontinuous length of a backing material, thereby transferring theprepreg segments from the conveyor belt to the backing material, andresulting in a continuous length of a backed cross-ply prepreg.
 2. Themanufacturing system of claim 1, wherein the cutting machine comprises:a nip roller assembly having opposing nip rollers positioned relative toeach other to define a roller interface configured to receive and clamponto the unidirectional prepreg, and feed a lengthwise section of theunidirectional prepreg into the cutting station.
 3. The manufacturingsystem of claim 2, wherein the cutting machine comprises: a backedunidirectional prepreg chuck configured to support a backedunidirectional prepreg drum containing a roll of the continuous lengthof the unidirectional prepreg supported on a backing layer; and abacking layer collection chuck configured to support a backing layercollection drum for collecting the backing layer as the backing layer ispeeled from the unidirectional prepreg.
 4. The manufacturing system ofclaim 3, wherein the cutting machine comprises: a pneumatic dancerassembly located between the backed unidirectional prepreg drum and thenip roller assembly, and configured to apply a constant tension load onthe unidirectional prepreg as the nip roller assembly draws theunidirectional prepreg through the cutting machine.
 5. The manufacturingsystem of claim 3, wherein: the backing layer collection drum is locateddownstream of the nip roller assembly and upstream of the cuttingstation, and is configured to peel the backing layer from theunidirectional prepreg as the unidirectional prepreg exits the niproller assembly prior to entering the cutting station.
 6. Themanufacturing system of claim 1, wherein: the cutting station isconfigured to cut the continuous length of the unidirectional prepreginto prepreg segments each having segment cut edges that are oriented atone of +45 degrees, −45 degrees, or 90 degrees, relative to thelengthwise direction of the unidirectional prepreg.
 7. The manufacturingsystem of claim 6, wherein the cutting station comprises: a cuttingassembly having a cutting device and a cutting device actuatorconfigured to translate the cutting device across a width of theunidirectional prepreg for cutting the unidirectional prepreg into theprepreg segments; and a turntable configured to support the cuttingassembly, and lock the orientation of the cutting device relative to thelengthwise direction of the unidirectional prepreg.
 8. The manufacturingsystem of claim 1, wherein the cutting machine comprises: a segmentpickup location where each prepreg segment is picked up by thepick-and-place system; and a segment delivery system configured totransport each prepreg segment from the cutting station to the segmentpickup location.
 9. The manufacturing system of claim 8, wherein thesegment delivery system comprises: a segment clamping system comprisinga pair of prepreg clamps configured to clamp onto opposing segment sideedges of the prepreg segment; a pair of linear guide rails respectivelysupporting the pair of segment clamps; and a clamp transporter actuatorconfigured to move the segment clamps along the linear guide rails, andthereby transport each prepreg segment from the cutting station to thesegment pickup location.
 10. The manufacturing system of claim 1,wherein the adhesion machine comprises: a backing material chuckconfigured to support a backing material drum, supporting a roll of thebacking material for spooling off of the backing material drum andfeeding through the cutting machine; a cross-ply material collectionchuck configured to support a cross-ply material collection drum forcollecting the backed cross-ply prepreg; and the backing material chuckand the cross-ply material collection chuck each having a chuckservomotor for respectively rotatably driving the backing material chuckand the cross-ply material collection chuck.
 11. A method ofmanufacturing a backed cross-ply prepreg, comprising: cutting, using acutting station of a cutting machine, a first continuous length of aunidirectional prepreg into first prepreg segments, each having anopposing pair of segment cut edges that are non-parallel to a lengthwisedirection of the unidirectional prepreg; picking up, using apick-and-place system, the first prepreg segments off of the cuttingmachine, and placing the first prepreg segments in end-to-end relationonto a conveyor belt of an adhesion machine, and in an orientation suchthat the segment cut edges are generally parallel to a lengthwisedirection of the conveyor belt; feeding, using the conveyor belt, thefirst prepreg segments to an adhesion station of the adhesion machine;and adhering, using the adhesion station, the first prepreg segments toa continuous length of a backing material.
 12. The method of claim 11,wherein adhering the first prepreg segments to the backing materialcomprises: adhering, using the adhesion station, the first prepregsegments to a continuous length of a backing layer that is devoid ofprepreg material.
 13. The method of claim 11, wherein adhering the firstprepreg segments to the backing material comprises: adhering, using theadhesion station, the first prepreg segments to a continuous length of aprepreg-backing assembly; and wherein the prepreg-backing assemblycomprises prepreg material backed by a backing layer.
 14. The method ofclaim 13, wherein adhering the first prepreg segments to theprepreg-backing assembly comprises: adhering, using the adhesionstation, the first prepreg segments to a continuous length of a backedcross-ply prepreg; and wherein the backed cross-ply prepreg comprises anend-to-end series of second prepreg segments on a backing layer.
 15. Themethod of claim 11, wherein after adhering the first prepreg segments tothe continuous length of the backing material, the method furthercomprising: feeding, using the conveyor belt, a second continuous lengthof unidirectional prepreg to the adhesion station; and adhering, usingthe adhesion station, the second continuous length of unidirectionalprepreg to the first prepreg segments on a continuous length of backinglayer.
 16. The method of claim 15, further comprising: positioning thecutting machine upstream of the adhesion machine, in a manner such thatthe direction of movement of unidirectional prepreg through the cuttingmachine is aligned with the direction of movement of the conveyor belt;mounting, on the adhesion machine, a roll of a backed cross-ply prepregcomprising the first prepreg segments on a continuous length of abacking layer; mounting, on the cutting machine, a roll of a secondcontinuous length of unidirectional prepreg; drawing the secondcontinuous length of unidirectional prepreg through the cutting machine,without cutting the second continuous length of the unidirectionalprepreg into prepreg segments; feeding, using the conveyor belt, thesecond continuous length of unidirectional prepreg to the adhesionstation, while drawing over the conveyor belt the continuous length ofthe first prepreg segments on the backing layer; and adhering, using theadhesion station, the second continuous length of unidirectional prepregto the continuous length of the first prepreg segments on the backinglayer, thereby resulting in two layers of prepreg segments on thebacking layer.
 17. The method of claim 11, wherein cutting theunidirectional prepreg comprises: cutting, via the cutting station, thecontinuous length of the unidirectional prepreg into prepreg segmentseach having segment cut edges that are oriented at one of +45 degrees,−45 degrees, or 90 degrees, relative to the lengthwise direction of theunidirectional prepreg.
 18. The method of claim 17, wherein cutting theunidirectional prepreg comprises: locking, via a turntable included withthe cutting station, an orientation of a cutting device relative to thelengthwise direction of the unidirectional prepreg; and translating thecutting device across a width of the unidirectional prepreg and alongthe orientation locked by the turntable.
 19. The method of claim 18,further comprising: transporting, using a segment delivery systemlocated adjacent to the cutting station, each prepreg segment from thecutting surface to a segment pickup location where the prepreg segmentis picked up by the pick-and-place system.
 20. A method of manufacturinga backed cross-ply prepreg, comprising: cutting, using a cuttingmachine, a first continuous length of a unidirectional prepreg intofirst prepreg segments, each having an opposing pair of segment cutedges that are non-parallel to a lengthwise direction of theunidirectional prepreg; picking up, using a pick-and-place system, thefirst prepreg segments off of the cutting machine, and placing the firstprepreg segments in end-to-end relation onto a conveyor belt of anadhesion machine, and in an orientation such that the segment cut edgesare generally parallel to a lengthwise direction of the conveyor belt;feeding, using the conveyor belt, the first prepreg segments to anadhesion station of the adhesion machine; adhering, using the adhesionstation, the first prepreg segments to a continuous length of a backinglayer, to thereby form a continuous length of an intermediate backedcross-ply prepreg; and adhering, using the adhesion station, either asecond continuous length of a unidirectional prepreg or an end-to-endseries of second prepreg segments to the first prepreg segments of theintermediate backed cross-ply prepreg, thereby resulting in a finalbacked cross-ply prepreg.